Method for the production of grounded panels and panel

ABSTRACT

A method for the production of grounded panels and to a panel having a core made from a wood material board. The method includes provision of a wood material board, application of a grounding in the form of a synthetic resin layer to at least one topside of the wood material board, application of a coating to an underside, lying opposite the topside of the wood material board, of the wood material board, pressing of the layer build-up consisting of the wood material board, grounding and coating under the influence of pressure and, if appropriate, temperature, division of the grounded and coated wood material board into individual panels, cutting machining of side faces of the panels for the incorporation of connection and locking means, and transport-safe packaging of the grounded panels.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. §119 of PatentApplication No. EP 10006779.2, filed on Jun. 30, 2010, and which isexpressly incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The invention relates to a method for the production of grounded panelsand to a panel having a core made from a wood material board.

DISCUSSION OF BACKGROUND INFORMATION

Laminate panels have already been known for some time in the prior artand nowadays many different applications, particularly as a replacementfor genuine wood panels, can no longer be imagined without them. Anespecially major field of use is the cladding of walls, ceilings andfloors, where the respective cladding is assembled from correspondingwall, ceiling and floor panels. Of course, in various fields of use, thesurface quality of laminate panels of this type has to satisfy variousrequirements. In this context, of course, a floor panel is exposed tosubstantially higher loads than, for example, wall or ceiling cladding.

The large-scale manufacture of laminate panels in this case involves awhole series of manufacturing steps which are largely identical for thevarious types of panel. First, a carrier board made, for example, from awood material, such as MDF, HDF or OSB, is provided, and this is coatedwith a plurality of layers of, if appropriate, different materials. Adecorative layer is supplied to an, if appropriate, pre-treated surfaceof a wood material board which has been provided as the core of thepanel to be produced. This may take place, for example, in the form of aprinted impregnated paper. The paper may also be printed directly ontothe topside of the wood material board. This may take place by means ofpressure rollers or a digital printer. Before the decoration is printedon, if appropriate, a grounding layer may also be applied to the surfaceof the wood material board. This decoration, particularly in so far asthe panel is to be used as a floor panel, has to be covered by at leastone wear layer. This may consist, for example, of a lacquer or of asynthetic resin. Advantageously, abrasion-resistant particles (forexample, corundum) are admixed and make the surface of the finishedpanel more resistant to load caused by walking on it. The layer build-upwith, if appropriate, a plurality of synthetic resin layers is finallypressed in a press under the influence of pressure and temperature, asdisclosed in EP 1 454 763 B1 to which reference is made in full.Subsequently, the still large-format, now coated wood material board isdivided into individual panels. After division into individual panels,connection means in the form of a tongue and groove with integratedlocking means are attached to the side faces, so that two panels can beconnected to one another by means of what is known as a “snapconnection” and can be interlocked in the vertical and horizontaldirection. In order to increase the realistic appearance of a laminatepanel, it is known, during the pressing of the layer build-up, to embossinto the topside a structure matching with the decoration(embossed-in-register). The laminate panel is thereby further equated,for example, to a genuine wood panel not only visually, but also byfeel.

Alternatively, coating may also take place with lacquer layers which aresubsequently cured, using high-energy radiation, for example electronand UV radiation. In this case, too, the large-format coated carrierboard is divided into panels only after the complete curing of thelayers applied.

In the market of laminate panels, in particular of floor panels, ademand for ever more diverse decoration variants has been seen. Thus,there is a demand not only for ever new wood imitations, but also,increasingly, for tile and brick decorations and also fantasydecorations in the most diverse possible forms. However, the conversionof a large-scale manufacturing plant for laminate panels to a newdecoration is relatively complicated and time-intensive and is thereforecostly. Moreover, for example when the decoration is applied in the formof a printed decorative paper to the wood material core, decorativepapers having diverse decorations have to be kept in stock. Thisrequires a large amount of storage space and also ties up anunnecessarily large amount of capital due to the large quantity ofdecorative papers to be kept in reserve.

If the decoration is printed directly onto the wood material board, forexample, via pressure rollers, a dedicated set of rollers has to be keptin reserve for each decoration, particularly the procurement of theserollers being cost-intensive. When a structure is to be embossed intothe topside, the press platens or press plates additionally have to beengraved cost-intensively. Moreover, the exchange of such press platensor press plates takes up time during which the production plant is at astandstill, and therefore the production costs for laminate panels rise.For the abovementioned reasons, it is economically expedient to producerelatively large quantities of laminate panels with a decoration onceselected before panels having another decoration are produced.

However, as well as the demand for ever more diverse decorationvariants, a growing reduction in the order sizes demanded is also to beseen. If, however, quantities of laminate panels with a specificdecoration which are too small are demanded, these cannot be producedeconomically. Individual orders therefore have to be “collected” by thetrade or by wholesalers, thus resulting for the end user in longdelivery times which are unacceptable particularly in the do-it-yourselfsector. Some of the demand consequently cannot be satisfied.

WO 2010/055429 A2 discloses a method for the production of a panel, inwhich, first, a grounding is applied to the topside of a large-formatwood material board. The wood material board thus grounded is, ifappropriate, pressed and is subsequently divided into individual panels.Only thereafter are the individual panels printed with the desireddecoration.

One disadvantage is that, although, by virtue of the method described inthe publication mentioned, the manufacturing plant itself can bedesigned to be smaller and more compact since the large-format woodmaterial boards no longer have to be printed, but, instead, smallerpanels, it is usually not possible to achieve faster delivery times forsmall batch sizes with individual decorations. If a customer orders asmall quantity of panels having a desired decoration, for example, froma panel dealer, the dealer will collect the incoming orders until heorders, overall, a sufficient number of panels from the panelmanufacturer. This is necessary in order to keep the transport costswithin justifiable limits, since laminate panels are transported, forexample, by large heavy goods vehicles which, so that they can operateefficiently, have to be loaded up to a certain capacity. Although theefficiency of the production method can be increased, using smallerplants, by virtue of the method described in WO 2010/055429 A2,flexibility, particularly regarding the fast delivery of small and verysmall batch sizes with individual decorations, is not achieved.

SUMMARY OF THE INVENTION

The problem to be solved according to the invention is, therefore, that,with the current procedure for producing the laminate panels required bythe end user, it is not possible for economic reasons to satisfy evenunusual customer wishes in a justifiable delivery time, in so far as aminimum batch size is not required, and that, even if the minimum batchsize were to be reached (for example, in the article sector, that is tosay the equipment of large offices or hotels), a longer delivery timehas to be taken into account, because, of course, the plant at the panelmanufacturer's first has to be converted accordingly, this not beingpossible within a few hours or days even in the worst order situation.

This problem can be solved in that the chain of the production processis interrupted and the dealer who receives the end user's wish for adecoration can apply the decoration himself to the panels. However, thedealer cannot handle and divide up wood material boards havingdimensions of several metres.

The object on which the invention is based is, therefore, to propose amethod which affords the possibility that a dealer to whom raw panelsare made available can subsequently provide these with a decorationaccording to the customer's wish, so that even very small order sizescan be produced flexibly and efficiently and at the same time thestorage and material costs are reduced.

The invention achieves the set object by means of a method for theproduction of grounded panels as semi-finished products, with the steps:

-   -   a) provision of a wood material board,    -   b) application of a grounding in the form of a synthetic resin        layer to at least one topside of the wood material board,    -   c) application of a coating to an underside, lying opposite the        topside of the wood material board, of the wood material board,    -   d) pressing of the layer build-up consisting of the wood        material board, grounding and coating under the influence of        pressure and, if appropriate, temperature,    -   e) division of the wood material board into individual panels,    -   f) cutting machining of side faces of the panels for the        incorporation of connection and locking means,    -   g) transport-safe packaging of the grounded panels.

This method affords a semi-finished product which in itself is not yetmarketable. However, the dealer can purchase semi-finished productsaccording to his requirements and store these on his premises. Thegrounded raw panels have already been produced by the manufacturer suchthat they fulfil their function in technical terms. They are thereforesuitable to be connected to one another by the connection and lockingmeans and to be used as wall, ceiling or floor panels. However, since awear layer is absent on the surface of the panels, the panels areexposed without the least possible protection to the stresses arisingparticularly in use as a floor panel. Moreover, they still have nodecoration. The grounded raw panels produced by means of the methoddescribed differ from finished panels only in the lack of a decorativelayer and the lack of at least one wear layer. The end user can pick outa decoration and a colour for the panels at the dealer's, and the dealerprints the individual ready-premade panels and seals the decoration.Customer wishes can thereby be attended to in an extremely flexible way,because the decoration can be combined in any desired way both in termsof the grain (wood decoration) and in terms of its colour. Themanufacture of the semi-finished product can produce efficiently becauseonly one type of panel is produced, this panel subsequently beingdelivered to the various dealers and stored there. The dealer can reducehis permanent stock of panels because he can of course fulfil eachcustomer wish directly.

The grounding may be applied in the form of a resin-impregnated paper orbe a synthetic resin applied directly to the topside. Alternatively, thegrounding may also be glued in the form of a film, coated particularlywith a synthetic resin, to the topside of the wood material board. Inthis case, an adhesive containing synthetic resin may also be used.

A structure is advantageously embossed into the grounding during thepressing of the layer build-up.

It proved to be especially advantageous if a quality check is carriedout after cutting machining.

In order to increase the printability of the surface of the groundedpanel to be produced, the grounding is advantageously coloured. In orderto improve the adhesion of the colour later to be applied on thegrounding, a primer may also be applied to the grounding.

Advantageously, the connection and locking means are milled out from thepanel. The panels are preferably cleaned before transport-safepackaging.

A panel according to the invention has a core made from a wood materialboard, on the topside of which only a grounding in the form of asynthetic resin layer and, if appropriate, a primer are applied, whichare pressed together with the core, a coating being applied on theunderside of the latter, and the connection and locking devices matchingone another being provided on mutually opposite side faces of the panel.

In this case, the roughness of a topside of the panel is advantageouslylower than 20 μm, especially preferably lower than 10 μm. ISO 4287-1 ismainly used as a test standard for the surface roughness. In order toensure that the panel has an especially good printability, for thecolour of a topside of the panel in the CIELAB colour range a brightnessparameter L is higher than 92, and a red-green value A lies between −5and +5, preferably between −2 and +2, and a yellow-blue value B liesbetween −15 and +15, preferably between −8 and +8. The standard DIN 6174serves as the standard basis for this colour range.

Advantageously, the topside of the panel has a structure. The connectionand locking devices may be formed in one piece with the wood materialboard. Especially preferably, connection and locking means which matchone another are provided on all the mutually opposite side faces.

The idea on which the invention is based is to make the production oflaminate panels, particularly for use as wall, ceiling and floorcoverings, more flexible, simpler and more cost-effective. For thispurpose, there is provision, within the framework of large-scalemanufacture, for producing only grounded panels as semi-finishedproducts. These have a core made from wood material which may bedesigned, for example, as OSB, MDF or HDF. This is coated with agrounding which is pressed together with the core of the wood materialboard. This gives rise to an easily printable surface which has therequired properties for ensuring an excellent printed image duringsubsequent printing. The grounding in the form of a synthetic resinlayer may in this case be applied in the most diverse possible forms tothe core made from wood material. It is conceivable, for example, forapplication to be in the form of a resin-impregnated paper, as asynthetic resin layer applied directly to the topside or in the form ofa finish film which is pasted on, for example, by means of an adhesivewhich may contain synthetic resin. All these applied groundings lead toan especially high surface quality. Depending on the grounding appliedto the wood material board, a coating is applied to the underside lyingopposite the topside of the wood material board. This coating may, forexample, assume the function of counteraction. This is necessaryparticularly when, during the drying of the applied grounding, a tensileforce is exerted upon the wood material board parallel to the surface ofthe latter. By corresponding coating being applied to the underside ofthe wood material board, a corresponding force is also exerted upon theunderside, so that arching or dishing of the wood material board iseffectively prevented.

If the grounding is applied, for example, in the form of a coated filmwhich is already finish-cured, the application of counteraction may beunnecessary. The coating applied to the underside can then, for example,prevent the uptake of moisture into the underside of the wood materialboard or merely have visual reasons. Thus, the acceptance of a panel onthe market by the end consumer can thereby be increased, in particular,in that the wood material board functioning as a core can no longer beseen even on the panel underside which is no longer visible in theinstalled state.

After the grounding has been applied to the topside and the coating tothe underside of the wood material board, the layer build-up is pressedtogether. This may take place under the influence of pressure andtemperature. This is necessary especially when at least one of theapplied layers is to be connected to the wood material core. If thegrounding is pasted on in the form of an already finish-cured film,pressing under pressure is sufficient.

After the pressing of the layer build-up, the still large-format coatedand pressed wood material board is divided into individual panels. Sidefaces of the panels are subsequently machined by cutting in order toincorporate connection and locking means. These connection and lockingmeans may consist of simple tongue-and-groove profilings or comprisecomplicated profiles, which ensure that two connected panels areinterlocked, for example, both in a vertical and in a horizontaldirection. Moreover, connection and locking means may also beincorporated in side edges of panels, into which still separateconnection elements which may consist, for example, of plastic areinserted. However, for installing or connecting two identical panels, itis advantageous if connection and locking means are worked, for examplemilled, out of the panel such that two identical panels can be connectedto one another and interlocked without additional connection elements.

The grounded panels thus produced are finally packaged in atransport-safe manner. A quality check may be carried out beforehand inorder to ensure that the grounded panels have as high a quality aspossible.

Since the laminate manufacturer produces only grounded panels to whichthe decorative layer does not have to be applied, both the stockkeepingand the material costs for the laminate manufacturer are reduced.Decorative papers having various decorations do not have to be kept instock or embossing rollers or embossing plates do not have to beprovided so that panels having different decorations can be produced. Asa result, both the required storage space and the tied-up capital aremarkedly reduced. Moreover, conversion times are avoided, since all thepanels have the same grounding. The production plant can thereby operatemore efficiently and the production costs are further reduced.

In order to ensure that the panels thus produced have especially goodprintability, the grounding is, in particular, coloured. In this case,in particular, a plurality of colours are possible, white or beige arementioned as examples. In this case, for example, coloured papers areused as the print base, the colour of which corresponds to the lightestcolour shade in the decoration to be printed on. If, as here, thedecoration to be applied is not yet known, a white or at least verylight grounding is therefore advantageous. However, every other colourmay likewise be envisaged as a grounding. In order to achieve specialeffects during the subsequent printing of panels pre-grounded in thisway, a structure may be introduced into the grounding. This takes placeadvantageously during the pressing of the layer build-up, in particularby embossing plates or embossing rollers used in this case.

However, pre-grounded panels produced in this way have, overall, a verysmooth surface. In particular, the surface is homogeneous and, in so faras the grounding is coloured, affords good covering. This, incombination with very low fault frequency due to surface faults or dirtparticles, is very important particularly for digital printing in whichthe pre-grounded panel is printed directly by means of a digitalprinter. A coloured wood material board may at least partially assumethe function of a grounding.

Owing to the very low surface roughness of the topside of the panel,which, for example, is less than 20 μm, especially preferably even lessthan 10 μm, a very good printed image is achieved during subsequentprinting. ISO 4287-1 is mainly used as a test standard for the surfaceroughness. If the wood material board or the grounding is coloured,advantageously, for the colour, a brightness parameter L is higher than92, a red-green value A lies between −5 and +5, preferably between −2and +2, and a yellow-blue value B lies between −15 and +15, preferablybetween −8 and +8. The specified values describe colours in the CIELABcolour range. DIN 6174 is the standard basis for this colour range. Thecolour of the grounding or of the coloured wood material board should inthis case correspond to the lightest colour shade in the decoration tobe applied. In so far as the latter is not yet known, as in the presentcase, it is of course appropriate to have an especially light,particularly white, surface colour.

Panels pre-grounded in this way are stored at the laminatemanufacturer's in a central store, for example a high-bay warehouse.They may previously be cleaned and packaged, in particular, such that,in further processing, they can be directly printed or processed,without the panels having to be cleaned again there. However, this mustbe reserved for only a single type of panel, so that space-intensivestorage of panels having different decorations, different surfacestructures or different surface qualities is no longer necessary.

The grounded panels are subsequently transported for further processing.This may, for example, involve a franchise operation associated with thelaminate manufacturer, home-improvement market, an interior decorator, adealer or a floor layer.

Here, the pre-grounded panels are unpacked from the transport-safepackaging. A decorative layer having a decoration according to thedirect customer's wish is subsequently applied to the grounding orprimer and covered by at least one wear layer.

The application of the decorative layer to the grounding or to theprimer may take place in various ways.

The decorative layer may, in particular, be printed directly onto thegrounding or primer. In this case, the pre-grounded panel passes througha printing unit which is advantageously a digital printer. It is therebypossible, in particular, to print different decorations onto differentpanels quickly and simply in succession, without the printing unithaving to be converted to the new decoration. Since only individualpanels have to be printed, not entire large-format wood material boards,as is customary in the prior art, the printing unit can be designed tobe small and compact and therefore space-saving and cost-effective.Alternatively, a decorative paper, which can be kept in the form oflarge rollers, may also be printed with a decoration and subsequently bepasted as a decorative layer onto the grounding or primer.

In both the instances, the decorative layer should be covered by atleast one wear layer. The number and type of wear layers applied dependin this case greatly on the planned place of use of the panels thusdecorated. Particularly in the case of wall and ceiling panels, it isoften sufficient when at least one wear layer covers the decorativelayer in a wipe-resistant manner. If, however, the printed panels areused as a floor panel, they are exposed to markedly higher load. In thiscase, in particular, a plurality of wear layers may be applied, to whichare admixed additives which increase the abrasion and/or scratchresistance of the topside of the then finished panels.

The at least one wear layer may in this case consist of a syntheticresin and, after being applied, may be cured under the influence ofpressure and temperature. During pressing, a structure, which, inparticular, matches the decoration of the decorative layer, may also beembossed into the at least one wear layer, in order thereby, forexample, to make the natural appearance of a genuine wood decorationcloser to reality.

Alternatively, the at least one wear layer may also be in the form of atleast one lacquer layer which is then cured, using high-energyradiation, for example electron or UV radiation. In this case, astructure-forming lacquer may also be applied, via which, during curing,a structure can be introduced into the at least one wear layer.

In curing by high-energy radiation and by pressing, in particular, awalk-on surface of the panel can be ensured. This takes place especiallywhen the panel is to be used as a floor panel.

In all the instances mentioned hitherto, in further processing, forexample in the home-improvement market, the decorative layer must becovered with at least one layer consisting of a synthetic resin orlacquer and subsequently be cured. For this purpose, a relatively highoutlay in terms of apparatus is required, which entails not only anincreased amount of space, but also relatively high investment costs.Moreover, it may be necessary to employ specialized personnel in orderto operate an apparatus for carrying out the method steps necessaryduring further processing, in particular during coating with syntheticresin or lacquer.

In an especially simple way, therefore, the decorative layer and the atleast one wear layer can be applied to the pre-grounded panel by meansof the following method steps. The at least one wear layer is providedon a carrier medium, for example a film. Should a plurality of wearlayers be necessary, these are located in reverse order on the carriermedium. The wear layer which is to form the topside in the finishedpanel is consequently located directly on the carrier medium and iscovered by the wear layers which lie under it in the finished panel.During further processing, various layer build-ups of the said at leastone wear layer on the carrier medium are kept in stock. The wear layerwhich is to cover the decorative layer in the finished panel istherefore located at the very top on the carrier medium in the layerbuild-up. This wear layer is then printed with the decoration to beapplied to the panel. The entire layer build-up is subsequently laidonto the grounding or primer such that the decoration then lies directlyon the grounding or primer and is covered by the at least one wearlayer. The carrier medium, for example the carrier film, is then locatedat the very top in the layer build-up. This layer build-up is thenpressed together with the pre-grounded panel. For this purpose, it issufficient if pressure is exerted upon the layer build-up. Since the atleast one wear layer which is located on the carrier medium is alreadyfinish-cured, action under the influence of increased temperature isunnecessary.

Subsequently, the carrier medium is pulled off, and the decorative layerand the at least one wear layer remain on the grounding or primer. It isthus possible to finish-refine the grounded panel, without supplyingliquid resins and lacquers which still have to be cured. Both the outlayin terms of apparatus and the investment volume and thereby markedlyreduced. In this embodiment, a structure, which matches, in particular,with the decoration of the decorative layer, may also be embossed intothe at least one wear layer during the pressing of the layer build-up.

An apparatus for refining a panel according to a method just describedcomprises in this case, in particular, a printing unit for printing thedecoration onto the grounding or primer, the decorative paper or thecarrier medium coated with the at least one wear layer, basically in anydesired colour and grain, and, moreover, an input device, by means ofwhich a selection of a decoration can be input, which is filed in a datastore in the form of electronic data. The apparatus comprises, moreover,an electrical control which is set up for reading the selecteddecoration out of the data store and for activating the printing unitsuch that the selected decoration is printed. Also, especiallyconveniently for the customer, this apparatus comprises an indicatordevice, via which the available decorations are indicated to the user.

In concrete terms, a method of this type may, for example, in ahome-improvement market, proceed as follows.

A customer who requires panels for a specific room size first obtainsinformation as to the number of panels which he needs. He can look atvarious decorations available for selection on an indicator device of anapparatus by means of which the grounded panel can be refined, asdescribed above. These decorations are filed in the form of electronicdata in a data store inside the apparatus. Alternatively, the apparatuscould, for example, also have a drive, for example for a CD, DVD or thelike. The customer can then also himself bring along a correspondingdata carrier on which decorations are stored in a predetermined dataformat. It is thus possible that the customer receives his completelyindividual decoration printed on panels.

After the customer has selected a decoration, he inputs this selectionvia the input device. The customer can also select how many panels areto be printed with the selected decoration and for which purpose hewishes to use these panels. Different wear layers are applied to thepanel, depending on the intended use which has been input.

Inside the apparatus, then, the desired decoration is applied to apre-grounded profiled panel and is covered with the combination of wearlayers which is considered necessary. After these are cured, ifnecessary, the customer can receive the panels printed with hisindividual decoration and can use them.

Should he notice in this case that he has not had sufficient panelsprinted or that it would be necessary, for example, to exchangeindividual panels which have become worn in the course of time, it ispossible at any time for him to reorder individual panels on anapparatus described.

As a result, flexibility in the production of laminate panels ismarkedly increased, and even the smallest application quantities havingthe most diverse possible decorations can expediently be producedefficiently.

BRIEF DESCRIPTION OF THE DRAWINGS

The method described is explained in more detail below with the aid ofthe following illustrative drawings in which:

FIG. 1 shows a diagrammatic illustration of an exemplary embodiment ofthe method for the production of grounded panels,

FIG. 2 shows a cross section through a panel produced by the methodaccording to FIG. 1, with an enlarged detail from it, and

FIG. 3 shows a diagrammatic illustration of an exemplary embodiment ofthe method for the refinement of a panel, such as is carried out duringfurther processing.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

FIG. 1 shows the diagrammatic illustration of a method for theproduction of a grounded panel as a semi-finished product, such as canbe carried out at the laminate manufacturer's. The processing directionis identified by arrows. The production method commences at the bottomleft in FIG. 1.

The method commences with a large-format wood material board 1. The woodmaterial board 1 is first fed to a pre-treatment device 2 in which thelarge-format wood material board 1 is prepared for carrying out themethod. Inside this pre-treatment device 2, for example, a topside ofthe wood material board 1 can be ground, or other smoothing of thesurface can take place. The wood material board 1 is prepared such thata material layer can be applied to the topside. For this purpose, thewood material board 1 is, for example, additionally cleaned and/orheated in the pre-treatment device 2. Moreover, quality assurance cantake place in order to ensure that the surface of the wood materialboard 1 is suitable for carrying out the method.

After the wood material board 1 has been prepared in the pre-treatmentdevice 2, it is fed to a grounding device 4. In the grounding device 4,a grounding in the form of a synthetic resin layer is applied to thetopside of the wood material board 1. This may take place, for example,by the application of a liquid synthetic resin layer or in the form of aresin-impregnated paper. Alternatively, for example, a film, which iscoated, in particular, with a synthetic resin, may also be glued to thetopside of the wood material board 1. An adhesive containing syntheticresin may also be used for this purpose.

After the wood material board 1 has passed through the grounding device4, it is fed to a drying device 6 in the exemplary embodiment shown inFIG. 1. Here, where appropriate, the grounding applied to the topside ofthe wood material board 1 in the grounding device 4 and taking the formof a synthetic resin layer is dried.

The coated wood material board 1 subsequently passes, in the methodshown in FIG. 1, through a short-stroke press 8 in which the woodmaterial board 1 is pressed under the influence of pressure andtemperature together with the grounding applied in the grounding device4 in form of a synthetic resin layer. Other forms of a press, forexample a belt press, may, of course, also be envisaged. Particularlywhen the grounding in the form of a synthetic resin layer is applied,already finish-cured, for example by means of a film, in the groundingdevice 4, if appropriate pressing only under the influence of pressure,without an increased temperature, is also sufficient.

The grounded wood material boards 1 pressed in the short-stroke press 8subsequently pass through a cutting-to-size device 10 in which thelarge-format wood material board 1 is divided into smaller panels 12.Profiles are subsequently incorporated at the side edges of the panels12 and make it possible to connect two identical panels 12 to oneanother. In this case, first, longitudinal profiles are milled out ofthe side faces of the panels 12 in a first milling device 14. It isconsequently possible to connect two identical panels 12 to one anotheralong their longer side faces.

The panels 12 subsequently pass through a second milling device 16 inwhich the short side faces are also provided with a profile, in thiscase a transverse profile. Identical panels 12 can therefore also beconnected to one another along their short side edges.

The grounded panels provided with connection means subsequently passthrough quality assurance 18 before they are packaged, in atransport-safe manner, in a packaging station 20.

During the pressing of the wood material board, coated with thegrounding, in a short-stroke press 8 or in another press apparatus, inparticular, a structure may be embossed into the grounding. Additionallyor alternatively to this, a relief may also be provided in thelarge-format wood material board 1. So that a relief can be embossedinto the wood material board 1, in particular, the wood material board 1may be sprayed with water before the grounding is applied in thegrounding device 4. An exemplary method was described in DE 10 2008 008240.

FIG. 2 shows a section along the line A-A from FIG. 1 through apre-grounded panel 12, and also in enlarged detail from this. The panel12 comprises a core 22 onto which a grounding 24 has been applied. Thetopside of the core 22 shows a relief 26 in the form of an unevensurface of the core 22. A structure 28, which has markedly finerelements than the relief 26 embossed into the core 22, is embossed intothe grounding 24.

FIG. 3 shows the diagrammatic illustration of a method for therefinement of a panel, such as may be carried out during furtherprocessing, for example by a franchisee associated with the laminatemanufacturer, in a home-improvement market or the like. The processingdirection is identified by arrows. The processing method commences atthe bottom left in FIG. 3.

The finish-grounded panels 102, coming from the laminate manufacturer intransport-safe packaging 104, are delivered for further processing. In afirst method step, the panels 102 are removed from this transport-safepackaging 104. In the exemplary embodiment of the method, as shown inFIG. 3, the panels 102 are subsequently fed to a cleaning apparatus 106in which the surface of the panels 102 is cleaned of dirt residues anddust which may possibly be adhering and is thus prepared for theapplication of the decorative layer. It is also conceivable, however,that the panels 102 have been cleaned suitably for later printing at thelaminate manufacturer's. These can then have been introduced, cleaned,into the transport-safe packaging 104. By virtue of transport pack 104being sealed, air-tight, in a film, for example, the situation can beruled out where the panels 102 subsequently have to be cleaned againbefore they are printed.

After the panels 102 have, where appropriate, passed through thecleaning apparatus 106, they are aligned in an acceleration section 108and spaced apart at the desired distance from one another. The panels102 are subsequently fed to a printing unit 110. Here, the surface ofthe panel 102 is printed with the decorative layer to be applied. Forthis purpose, in the exemplary embodiment shown in FIG. 3, the printingunit 110 has three printing heads 112. Depending on the desireddecoration, the printing unit 110 may also have more or fewer printingheads 112. Connected to the printing unit 110 is an electronic dataprocessing device 114. This has an input device, not shown in FIG. 3,via which the user of an apparatus for carrying out the method canselect the desired decoration.

For this purpose, the electronic data processing device 114 has anindicator device 116, via which the available decorations filed, forexample, on an electronic storage medium are indicated to the user. Theuser can select from this selection the decoration which he would liketo have printed onto his panels.

In the exemplary embodiment shown in FIG. 3, the electronic dataprocessing device 114 additionally has a scanner 118. If, then, a userof the apparatus for the refinement of the panel 102 brings with him anindividual decoration, for example in the form of a paper print-out, thepattern can be read via the scanner 118 into the electronic dataprocessing device 114 and can be applied to the topside of the panel viathe printing heads 112 of the printing unit 110. The user is thereforeno longer restricted to the pattern selection filed in the electronicdata processing device 114.

Moreover, in the exemplary embodiment shown in FIG. 3, the electronicdata processing device 114 has a camera 120. Via this camera 120, it ispossible, for example, to photograph decorations of surfaces which, forexample, the customer has brought along, but which cannot be scanned,and thereby to read these decorations into the electronic dataprocessing device. Even decorations of this type can be applied to thetopside of the panel 102 via the printing heads 112 of the printing unit110. For example, a CD-ROM drive may also be provided, via which thecustomer can cause a decoration stored in a defined format on a CD-ROMto be read into the data processing device 114.

So that the panels 102 remain exactly in alignment when the decorationis being applied by the printing heads 112, the said panels are guidedin the printing unit 110 by guide elements 122.

In order to ensure as optimal a result as possible, the decorationproposals filed in the data store of the electronic data processingdevice 114 are optimized to the possible formats of the panels 102 to beprinted. Individual decorations of a user of the apparatus described,which have been read into the electronic data processing device 114, forexample, via the scanner 118, the drive or the camera 120, can beadapted to the panel formats. The decoration selection filed in the datastore of the electronic data processing device 114 can in this case, inparticular, be updated online.

After the topside of the panels 102 has been printed with a decoration,the panels 102 leave the printing unit 110 and are fed to a coatingapparatus 124. In the exemplary embodiment illustrated in FIG. 3, thiscomprises three applicator devices 126, via which a wear layer can ineach case be applied to the topside of the panel. The applicator devices126 are controlled by a second electronic data processing device 128.This has a merge program by which the composition of the individual wearlayers is controlled. The second electronic data processing device 128can in this case activate various reservoirs 130 and mix their contentsto form the wear layer desired in each case. One of these reservoirs 130contains the basic substance of each individual wear layer which, forexample, may be a synthetic resin or else a lacquer. The furtherreservoirs 130 contain, for example, hardeners, corundum for increasingthe abrasion resistance of the finish-coated panel and further additiveswhich are selected according to the intended use of the then finishedpanel.

As in the printing unit 110, different panel formats can also beprocessed in the coating apparatus 124. The panels 102 to be coated arealso guided via guide elements 122 inside the coating apparatus 124. Apossible layer build-up consists of a plurality of layers ofradiation-hardenable lacquer. In this case, for example, two layers ofan anti-abrasive UV basic lacquer are applied by means of a rollersystem in an application quantity of, for example, 35 g/m² to thetopside, to be coated, of the panel 102. Each applicator device 126 isin this case designed in the form of a roller system. After the twolayers of the anti-abrasive basic lacquer are applied, two furtherlayers of a UV yellow earth size may likewise be applied in each case bymeans of an applicator device 126 designed as a roller system. Theapplication quantity here amounts, for example, to 15 g/m² per yellowearth size layer. Finally, via a further applicator device 126, a layerof a UV covering lacquer is applied in an application quantity of, forexample, 35 g/m². If appropriate, before each lacquer layer is applied,the lacquer layer previously applied is cured by means of UV or electronbeams. In the exemplary embodiment shown in FIG. 3, the various wearlayers, which, in particular, may also consist of a synthetic resin, areapplied directly in succession, without the wear layer previouslyapplied by an applicator device 126 being dried.

An applicator device 126 in the form of rollers may in this case beoperated both in synchronism and in opposition. So that as many panels102 as possible can be coated in a predetermined time, high speeds ofadvance of applicator devices 126 of this type are preferred. Inparticular, speeds of advance of between 10 m/min and 30 m/min aresuitable here.

If lacquer layers are applied as wear layers in the coating apparatus124 by the applicator devices 126, these applicator devices 126 may alsobe designed in the form of a splash or spray-lacquering device, adigital printing head, a casting head or a vacuum apparatus. Each layerapplied may contain abrasion-resistant particles, for example corundum,or other additives. These depend on the subsequent use of the thenfinished panel.

After the panels 102 have left the coating apparatus 124, they are ledto a first curing device 132. In the exemplary embodiment shown in FIG.3, the wear layers which are applied in the coating apparatus 124 andmay be present, for example, in the form of a lacquer are simply gelledmerely by high-energy beams, for example electron or UV beams.Subsequently, in an embossing device 134, a structure is embossed intothe topside of the coated panel, that is to say the wear layers. Thisstructure, in particular, matches with the selected decoration of thedecorative layer applied in the printing unit 110.

The embossing of the structure may in this case take place, for example,by means of a structured roller, a structured belt or a structure donorpaper or structure donor film.

Alternatively, an overlay paper sheet may also be laid in place andsubsequently pressed in a short-stroke press under the action ofpressure and heat. In this case, in particular, structures are providedin the press plates and, during pressing, are embossed into the topsideof the panel 102.

Particularly when lacquers are used as wear layers, a structure-formingquantity of lacquer may also be applied by means of a, for example,digitally activated printing head. Alternatively, a means which disturbsthe flow of the lacquer may also be envisaged. This means, too, may beapplied, using a digitally activated printing head. By a printing headof this type being used, it is possible to apply the means or thelacquer only at specific locations on the surface of the panel 102 andthus generate structure-forming depressions and elevations. If thestructure embossed into the topside is to match with the decoration ofthe decorative layer, the panel 102 must be aligned before it passesthrough the embossing device 134. In the exemplary embodimentillustrated in FIG. 3, after passing through the embossing device 134,the panel 102 passes through a second curing device 136. Here, the, ifappropriate, gelled wear layers are cured completely, so that a surfacesuitable for the in each case chosen use of the panel 102 is obtained.

Subsequently, the panels 102 pass through quality assurance 138, ifappropriate labelling 140 or the like, if appropriate additionally alsoa cleaning device, and are finally packaged and can be taken away by thecustomer.

Especially advantageously, the electronic data processing device 114 iscoupled to the second electronic data processing device 128. Then,during further processing, a customer is given various selectionpossibilities, for example, by means of a program. He can in this case,for example, choose whether the panel 102 is to be used privately orcommercially, in a dry or a damp area, with references to variouscommercial classes of use being given. Moreover, the customer can decidewhether the panel 102 to be coated will later be a floor, wall orceiling panel. This information is important for the wear layers to beapplied in the coating apparatus 124. In an apparatus for the refinementof a panel, the wear layers necessary for achieving a specific wearclass, for example AC3 according to DIN EN 13329, are then appliedautomatically together with the required aggregates and additives.Lacquering and hardening in this case take place automatically.

Moreover, the customer can select the format of the panel and thethickness of the carrier board and also the desired decoration and,where appropriate, a structure to be embossed. By means of thesecustomer stipulations, both the printing unit 110 and the coatingapparatus 124 can be set to the thickness and format of the panels 102to be coated.

Further selection possibilities for the customer are, for example, theselection of specific packaging. Thus, the panels may be introducedsimply into a cardboard carton or may be packaged so as also to beprotected against splashes of water by means of a film, for example ashrink film. Moreover, the customer can, for example, decide whether hewould like to take the finished panels away immediately or fetch themhimself at a later time or whether they are to be delivered by anoutside firm.

An installation option by a specialized firm may also be envisaged.Moreover, the customer can, where appropriate, select warrantee andguarantee options for an extra price and, if appropriate, decide whetherhe buys or rents the panels.

The lacquering and curing of the lacquer layers may take placeautomatically inside a plant for the refinement of a panel according tothe method described. Since the lacquers or resin layers used, which areapplied as wear layers, can be optimized for this application,particularly in terms of their viscosity, a smooth application, withoutextra or fewer applications of lacquer at the start and end of thepanels 102 to be coated, can be ensured. In order to protect theconnection and locking elements already integrally formed on the panels102, masks may be used which prevent the soiling or contamination ofthese connection and locking elements. Particularly during the curing ofapplied lacquer layers, the adhesion of the individual layers to oneanother and final curing can be implemented and ensured by setting thebeam intensity. For multiple applications, the corresponding plant part,that is to say the coating apparatus 124 and the first curing device 132and second curing device 136, can be passed through several times.

For the optimum utilization of a plant of this type, a plurality ofapplications may be produced directly in succession. After anapplication is concluded, fully automatic cleaning, in particular, ofthe applicator devices 126 may take place, so that a clean plant can beprovided for the next application.

The method described has a series of advantages. After the finishing ofthe surface, the customer can take the finished product away immediatelyin the desired quantity and quality. Consequently, in particular, theproblem of small quantities is solved for the laminate panelmanufacturer, since he simply has to produce one type of panel, to beprecise pre-grounded and structured panels, where appropriate, indifferent dimensions. Since the connection and locking means are milledonto pre-grounded panels or incorporated in another form in this method,the milling waste which occurs is reduced, in particular, in that nodecorative paper or overlay paper is applied to the pre-grounded panels.The production costs are thereby markedly reduced. Moreover, by virtueof the method described, transport damage or transfer faults in ordersare markedly reduced, since the customer can stand directly in front ofthe apparatus and input his wishes. It is no longer necessary for anorder to be transferred to a laminate manufacturer.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed as limitingof the present invention. While the present invention has been describedwith reference to an exemplary embodiment, it is understood that thewords which have been used herein are words of description andillustration, rather than words of limitation. Changes may be made,within the purview of the appended claims, as presently stated and asamended, without departing from the scope and spirit of the presentinvention in its aspects. Although the present invention has beendescribed herein with reference to particular means, materials andembodiments, the present invention is not intended to be limited to theparticulars disclosed herein; rather, the present invention extends toall functionally equivalent structures, methods and uses, such as arewithin the scope of the appended claims.

1. A method for the production of grounded panels as semi-finishedproducts, comprising, in order: a) provision of a wood material board, bapplication of a grounding in the form of a synthetic resin layer to atleast one topside of the wood material board, c) application of acoating to an underside, lying opposite the topside of the wood materialboard, of the wood material board, d) pressing of the layer build-upconsisting of the wood material board, grounding and coating under theinfluence of pressure and, if appropriate, temperature, e) division ofthe grounded and coated wood material board into individual panels, f)cutting machining of side faces of the panels for the incorporation ofconnection and locking means, and g) transport-safe packaging of thegrounded panels.
 2. The method according to claim 1, wherein thegrounding is applied in the form of a resin-impregnated paper.
 3. Themethod according to claim 1, wherein the grounding is a synthetic resinapplied directly to the topside.
 4. The method according to claim 1,wherein the grounding is glued in the form of a film to the topside ofthe wood material board.
 5. The method according to of claim 1, wherein,during pressing, a structure is embossed into the grounding.
 6. Themethod according to claim 1, wherein, after cutting machining, a qualitycheck is carried out.
 7. The method according to claim 1, wherein thegrounding is colored.
 8. The method according to claim 1, furthercomprising applying a primer to the grounding.
 9. The method accordingto claim 1, wherein the connection and locking means are milled out ofthe panel.
 10. The method according to claim 1, wherein the panels arecleaned before transport-safe packaging, in order to prepare the panelsfor a subsequent printing operation.
 11. A panel with a core made fromwood material, on a topside of which only a grounding in the form of asynthetic resin layer and, when required, a primer are applied, whichare pressed together with the core, a coating being applied to theunderside of the latter, and connection and locking devices matching oneanother being provided on at least two mutually opposite side faces. 12.The panel according to claim 11, wherein a roughness of a topside of thepanel is lower than 20 μm.
 13. The panel according to claim 11, whereina roughness of a topside of the panel is lower than 10 μm.
 14. The panelaccording to claim 11, wherein, for a colour of a topside of the panelin the CIELAB colour range, a brightness parameter L is higher than 92and a red-green value A lies between −5 and +5, preferably between −2and +2, and a yellow-blue value B lies between −15 and +15, preferablybetween −8 and +8.
 15. The panel according to claim 11, furthercomprising a structure in the topside of the panel.
 16. The panelaccording to claim 11, wherein the connection and locking devices areformed in one piece with the core made from wood material.
 17. The panelaccording to claim 11, wherein connection and locking means matching oneanother are provided on all the mutually opposite side faces.